KMG Rompetrol & Grace: Increase FCC Profitability …...•KMG Rompetrol is among the 5 highest FCCU...

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1 © 2018 W. R. Grace & Co. | Confidential Increase FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018 KMG Rompetrol & Grace: Increase FCC Profitability by Operating in Propylene Maximization Mode Rafael González Sánchez | Regional Technical Sales Manager RefComm Conference | Valencia, 2 nd 4 th October 2018

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  • 1 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    KMG Rompetrol & Grace: Increase FCC Profitability by

    Operating in Propylene Maximization Mode

    Rafael González Sánchez | Regional Technical Sales Manager

    RefComm Conference | Valencia, 2nd – 4th October 2018

  • 2 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    Poll Question

    • European refineries which are integrated with

    petrochemical facilities will be better positioned for the

    future market challenges.

    a) True

    b) False

    c) It depends

  • 3 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    KMG Rompetrol

    Refining and petrochemicals is one of the main

    business units of KMG International

    • It has two Production facilities: Petromida

    consisting of a Refinery and Petrochemical

    Complex and Vega Refinery.

    • The refinery operates integrated petrochemical

    production facilities, making propylene a key

    product for the refinery

    • The fluid catalytic cracking (FCC) unit is the main

    contributor to the refinery’s production of light

    olefins, especially propylene.

    Nelson Complexity Index 10.5

    Unit design UOP SBS

    Unit capacity, bbl/day 24100

    FCCU unit process 100 % hydrotreated feed

    Crude processed are typically URAL with blend to other

    opportunity crudes like Kirkuk, Azeri, Siberian, CPC

  • 4 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    KMG Rompetrol

    Refining and petrochemicals is one of the main

    business units of KMG International.

    • It has three production units – Petromidia

    refinery (in Navodari), Vega refinery (in Ploiesti)

    and the Petrochemicals division.

    • Petromidia is the most efficient refinery in

    Romania and the 9th out of 250 refineries in

    Europe and Africa.

    • The refinery operates integrated

    petrochemical production facilities, making

    propylene a key product for the refinery

    • The fluid catalytic cracking (FCC) unit is the

    main contributor to the refinery’s production of

    light olefins, especially propylene.-

    Annual Refining Capacity

    (MTmn)

    Nelson Complexity Index 9.7

    FCCU process hydrotreated

    feed100%

    Unit design UOP SBS

    Typical feed process

    URAL/CPC/Kirkuk76%/6%/20-30%

  • 5 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    Global Cumulative Growth in Petchem

    Demand

    • 2016 - Petchem make up 12% of crude oil market.

    • 2035 - Petchem will make up almost 50% demand of crude oil growth

  • 6 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    FCCU Propylene Yields

    • Yields of over 12 wt% have been achieved with Grace’s latest generation

    of propylene maximization technology.

    • KMG Rompetrol is among the 5 highest FCCU propylene yields in EMEA

    Refineries in EMEA are utilising Grace solutions

    to achieve excellent propylene yields

    9.4

    7.7

    2

    4

    6

    8

    10

    12

    14

    50 55 60 65 70 75 80 85

    C3

    = yi

    eld

    s, w

    t%

    Conversion, wt%

    Ecat ACE Global Benchmark ACHIEVE vs. Base Case Catalysts

    Base Case ACHIEVE

  • 7 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    ACHIEVE® – Five steps to success

    Continuous analysis of ACHIEVE is being conducted to validate the

    increased profitability of the KMG Rompetrol FCCU.

    Internal screening by Grace before offering ACHIEVE - screening study using the ACE® pilot

    plant to identify most suitable formulation – July 2015

    New technology proposed – September 2015

    Grace Management of Change presented and discussed – September/December 2015

    First delivery of new catalyst to KMG Rompetrolrefinery – July 2016

    ACHIEVE results are showing the expected benefits in propylene yield and C4’s selectivity – test run

    January 2017

  • 8 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    ACHIEVE – ACE results

    Key Unit Objectives

    • Maximum Propylene Yield

    (min.10 wt% of FF)

    • Maximum Iso-Butylene Yield

    • Maximize LCO

    • High RON

    • Higher dcoke

    • Minimize dry gas

    Improved performance with selected FCC catalyst tested by

    Grace’s pilot plant

    -1.5 -1 -0.5 0 0.5 1 1.5

    C/O

    Coke

    dcoke

    Dry Gas

    LPG

    Gasoline

    LCO

    HCO

    C3=

    iC4=

    total C4

    iC4=/total C4

    iC4=/LPG

    ACE Performance Deltas

    Key objectives

    wt %

  • 9 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    Ecat comparison BASE vs. ACHIEVE

    ACE Ecat results confirm improved olefins yields

    1.500

    1.700

    1.900

    2.100

    2.300

    2.500

    2.700

    2.900

    3.100

    3.300

    71.0 72.0 73.0 74.0 75.0 76.0

    IC4

    =, w

    t%

    Conversion, wt%

    ECAT Iso-butylene, wt%6.00

    6.50

    7.00

    7.50

    8.00

    8.50

    9.00

    9.50

    10.00

    10.50

    11.00

    71.0 72.0 73.0 74.0 75.0 76.0

    Pro

    pyle

    ne

    ye

    ild

    , w

    t%

    Conversion, wt%

    ECAT Propylene Yields (wt%) ACHIEVE Base catalyst

  • 10 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    ACHIEVE – Unit Performance

    ACHIEVE catalyst formulation provides significant bottoms

    upgrading

    42

    46

    50

    54

    80.0 85.0 90.0 95.0

    Ga

    so

    lin

    e, w

    t%

    Conversion, wt%

    0

    2

    4

    6

    8

    10

    80.0 85.0 90.0 95.0

    Slu

    rry,

    wt%

    Conversion, wt%

    0

    4

    8

    12

    80.0 85.0 90.0 95.0

    LC

    O,

    wt%

    Conversion, wt%

    0.0

    1.0

    2.0

    3.0

    4.0

    5.0

    80.0 85.0 90.0 95.0

    Dry

    Ga

    s, w

    t%

    Conversion, wt%

    ACHIEVE Base catalyst

  • 11 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    ACHIEVE – Unit Performance

    Key refinery objectives of increased propylene and

    isobutylene yields have been achieved

    6

    8

    10

    12

    80 82 84 86 88 90 92 94

    Pro

    pyle

    ne

    , w

    t%

    Conversion, wt%

    0.0

    1.0

    2.0

    3.0

    4.0

    80 82 84 86 88 90 92 94

    Iso

    -Bu

    tyle

    ne

    , w

    t%

    Conversion, wt%

    20

    24

    28

    32

    80 82 84 86 88 90 92 94

    LP

    G,

    wt%

    Conversion, wt%

    0

    0.1

    0.2

    0.3

    0.4

    0.5

    80 82 84 86 88 90 92 94

    iC4

    = / C

    4=

    e, w

    t%

    Conversion, wt%

    ACHIEVE Base catalyst

  • 12 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    ACHIEVE – Unit Performance

    Compared to the Base catalyst system,

    the ACHIEVE catalyst:

    • provided higher iso-butylene and propylene yields as expected.

    • 11.0 wt% propylene yield is achieved

    ACHIEVE test run results at maximum unit throughput and max.

    severity demonstrate higher refinery profitability for 2.3 M$/y

    ECAT Properties: Activity, wt% 73.5 -75.0 UCS, Å 24.26 SA, m2/g 182 - 192

    Operating conditions:

    Unit throughput, t/h 142

    ROT, o C 541

    FPH temperature, o C 215

    Specific Gravity 0.885

    ZSM- Additive (OlefinsUltra HZ), % 7

    Operation Mode Full Burn

    Performance ACHIEVE vs. Base

    Dry Gas, wt% 0.29

    C3=, wt% 1.26

    iC4= , wt% 1.05

    LPG, wt% 1.68

    Total Naphta, wt% -1.77

    LCO, wt% 2.03

    Slurry, wt% -2.10

    Coke, wt% -0.13

  • 13 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    Outlook

    • The most profitable refineries are the ones that leverage their

    flexibility to capture market opportunities.

    • Increased profit of 2.3M $/y is calculated using refinery PIMS

    model.

    • Rompetrol could even further optimize performance and

    improve profitability through additions of Grace’s latest

    generation ZSM-5 additive, OlefinsUltra® XZ.

    • Refinery plan is to increase downstream petrochemical unit

    capacity for additional 15-20% to further increase LPG

    production.

  • 14 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018

    Rafael González Sánchez | Regional Technical Sales Manager

    Refining Technologies - [email protected]

    www.grace.com

    Valentin Nilca | Senior Process Engineer Ljubica Simic | Technical Sales Manager

    KMG Rompetrol Rafinare Refining Technologies - [email protected] [email protected]

    www.rompetrol.com www.grace.com

    mailto:[email protected]://www.grace.com/mailto:[email protected]:[email protected]://www.rompetrol.com/http://www.grace.com/